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Engineering for reality, not just the screen.

Engineering for reality, not just the screen.

Engineering for reality, not just the screen.

The hardest part of hardware isn’t the initial design—it’s scaling it. We help innovators avoid the traps that kill startups.

The hardest part of hardware isn’t the initial design—it’s scaling it. We help innovators avoid the manufacturing traps that kill startups. From streamlining assembly sequences and managing part EOL, to removing costly unnecessary tolerances, we engineer products to be built, scaled, and profitable.

The hardest part of hardware isn’t the initial design—it’s scaling it. We help innovators avoid the manufacturing traps that kill startups. From streamlining assembly sequences and managing part EOL, to removing costly unnecessary tolerances, we engineer products to be built, scaled, and profitable.

Let’s Talk

From napkin sketch to scale

01 / Idea

01 / Idea

01 / Idea

Capture the problem, constraints, and first technical path.

Capture the problem, constraints, and first technical path.

02 / Prototype

02 / Prototype

02 / Prototype

Test the form, materials, assembly, and manufacturability.

Test the form, materials, assembly, and manufacturability.

03 / Scale

03 / Scale

03 / Scale

Prepare the BOM, vendors, quality plan, and production handoff.

Prepare the BOM, vendors, quality plan, and production handoff.

Prepare the BOM, vendors, quality plan, and production handoff.

Three ways we help

From first principles to operational scale.

From first principles to operational scale.

From first principles to operational scale.

We bring structure to ambiguous product challenges, with hands-on engineering judgment and a clear path forward.

We bring structure to ambiguous product challenges, with hands-on engineering judgment and a clear path forward.

Manufacturable Concept Design

Manufacturable Concept Design

Manufacturable Concept Design

Start with a foundation meant to be built, not just rendered. A beautiful concept is useless if it’s too expensive to produce. We validate your idea and establish an architecture that works in the real world. By introducing manufacturing constraints early, we ensure you don’t fall in love with a design that can’t be built.

• Technical feasibility & architecture

• Early-stage material & process selection

• Proof-of-concept prototyping

Design for Manufacturing & Assembly (DFMA)

Design for Manufacturing & Assembly (DFMA)

Design for Manufacturing & Assembly (DFMA)

Stripping out complexity to protect your profit margins. We optimize your product for the factory floor, streamlining assembly to reduce labor time and applying smart, functional tolerancing. We eliminate overly tight specs that inflate tooling costs and drive up factory rejection rates.

• Tolerance analysis & yield optimization

• Assembly sequence planning

• Detailed CAD optimized for specific tooling

Production Scaling & Cost Reduction

Production Scaling & Cost Reduction

Production Scaling & Cost Reduction

Turning expensive prototypes into profitable, scalable products. Whether you’re scaling your first run or rescuing margins on an existing product, we help you cross the finish line. We optimize your BOM, plan for component EOL, and ensure a seamless handoff to contract manufacturers.

• BOM (Bill of Materials) cost reduction

• Component EOL & lifecycle planning

• Manufacturing handoff & vendor support

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Portfolio

Portfolio

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Road Armor: INEOS Grenadier

Generated full engineering packages of a complete series of Molle panels for the INEOs Grenadier.

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Virgin Galactic: Spaceship Delta

Delivered comprehensive engineering and manufacturing solutions backed by hands-on leadership of complex aerospace programs, specializing in product development, DFMA, GD&T, production planning, and manufacturing execution.

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Skyways: v3 Drone

Helped the Skyways orgainazation accelerate product development and manufacturing by implementing DFMA, optimizing ERP and PLM systems, and improving production processes from prototype through full-rate manufacturing.

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Shield AI: VBAT

Scaled from prototype to production by optimizing manufacturing processes, implementing ERP and quality systems, designing cost-effective tooling, and applying DFMA to improve efficiency and profitability.

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Martin UAV: SuperBat

Successfully scaled manufacturing organizations through standardized work, DFMA, composite tooling design, ERP implementation, and lean manufacturing strategies that improve quality and reduce labor costs.

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Virgin Galactic: Spaceship Unity

Led manufacturing engineering initiatives for advanced aerospace programs, specializing in MBOM management, assembly planning, composite tooling, additive manufacturing, lean systems, and enterprise manufacturing software.

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Aerovironment: Global Observer

Directed the manufacturing, structural testing, and flight support of large composite UAV wing systems, including load testing, instrumentation, and field operations

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Adam Aircraft: A700

R&D, fabrication, and Flight Test

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Adam Aircraft: A500

Fabrication, Modification, Flight Test, Production aids, and Build Packages

Have a product challenge?

Let’s turn the next unknown into an engineering plan.

Let’s turn the next unknown into an engineering plan.

Let’s turn the next unknown into an engineering plan.

Bring the sketch, prototype, manufacturing question, or scaling bottleneck. We’ll help shape a clear, practical next step.

Bring the sketch, prototype, manufacturing question, or scaling bottleneck. We’ll help shape a clear, practical next step.

Let’s Talk

Prefer to start small? Send a short summary of the product, constraint, and decision you need to make next.